Dematic delivered a goods-to-person (GTP) automation system for Metcash’s new 115,000 square metre distribution centre in Truganina, consolidating the distributor’s Victorian operations into a single site. The facility replaced a multi-shed layout in Laverton and featured an integrated solution aimed at improving efficiency and supporting future growth.
Previously, Metcash managed grocery, liquor, convenience and perishable goods across separate Laverton warehouses. Its existing mini-load system, installed almost 20 years earlier, had become difficult to maintain and limited flexibility across the network.
To address these challenges, Metcash partnered with Dematic to implement a modular, high-density automation system. At the centre of the solution was a Multishuttle system with seven active pick stations and built-in scalability. Dematic’s Inter-Aisle Transfer (iAT) allowed SKUs to be retrieved dynamically across the network of aisles, increasing flexibility during order fulfilment.
The system included sortation buffers equipped with Flex Shuttles to handle a wide range of product sizes, including fragile goods such as wine bottles. According to Metcash, this capability was a key consideration during the design and tender process.
Operator safety and ergonomics were also prioritised. Adjustable platforms and powered lift-and-rotate tables were incorporated at Gen3 pick stations. “The ergonomic improvements have made a clear difference to our team on the floor,” says Victor Cleves, head of DC automation and design at Metcash.
The solution was designed to integrate with separate warehouse management systems for grocery and liquor, ensuring continuity without disrupting workflows. The transition to the new site was staged over four phases, culminating in a planned automation cutover. Operations ceased at Laverton on a Thursday and resumed the following Monday from Truganina.
Structured training and gradual commissioning supported the switchover. “Our team had already gained hands-on experience by the time the system went live,” says Cleves. “It gave us the confidence we needed for a smooth transition.”
Metcash also cited the benefit of Dematic’s local support network. “Access to on-site expertise made a significant difference,” says Andrew North, state logistics manager for Victoria. “We had what we needed when we needed it – from spare parts to technical support.”
Since go-live, Metcash has reported improved pick rates, shift optimisation, and better visibility over maintenance planning. Dematic also provided a ‘Lifecycle cost plan’ covering projected investment across five, 10 and 15 years.